US20020167103A1

US20020167103A1 - Method for introducing additives

Info

Publication number: US20020167103A1
Application number: US09/936,039
Authority: US
Inventors: Georg Ickinger
Original assignee: Sulzer Chemtech AG
Current assignee: Sulzer Chemtech AG
Priority date: 2000-01-10
Filing date: 2001-01-04
Publication date: 2002-11-14
Also published as: ES2274862T3; DE50111437D1; EP1724003A2; JP2003529444A; EP1724003A3; US6866171B2; US7438840B2; WO2001051267A2; EP1159115B1; WO2001051267A3; US20050077642A1; CA2366321A1; CA2366321C; AU2651701A; EP1159115A1

Abstract

The invention relates to a method for introducing additives into flowing or fluidized media. The spatially predetermined position of the additives in the flowing material, also called fluid bed, is obtained by controlling the pulsating injection, The introduction and exact dosing of additives, that is hardeners, dyes, gas producers and softener for instance, into a liquid plastic stream or metal stream (10) for instance or the fluid bed of bulk material, such as powder, granules and pellets, is carried out by means of an injector. The invention is used in melting units, in hot channel systems, in tools, componens of tools and injection moulding machines, extruder-, injection moulding-, pelleting-, burner- and injection arrangements. The nozzle needle (3) of at least one nozzle (2) respectively is variable and highly precisely moved for the introduction by means of a device and in such a way that additive (17) is dosed exactly in relation to the volume flow of the medium and that a pulsating stream (18, 36) is injected into the medium flowing past, by means of at least one well-aimed nozzle opening (4). The additives are bosed by means of a pressure that can be adjusted variable, pulse width and puls frequenmcy. The desired homogenous distribution is obtained by the penetrating injection jet (37) during compounding for instance.

Description

The invention relates to a method for introducing additives into flowing or fluidised media. The spatially predetermined position of the additives in the flowing material, also called fluid bed, is obtained by controlling the pulsating injection, The introduction and exact dosing of additives, that is hardeners, dyes, gas producers and softener for instance, into a liquid plastic stream or metal stream for instance or the fluid bed of bulk material, such as powder, granules and pellets, is carried out by means of an injector. The invention is used in melting units, in hot channel systems, in tools, components of tools and injection moulding machines, extruder-, injection moulding-, pelletizing-, burner- and injection arrangements. The nozzle needle of at least one nozzle respectively is variable and highly precisely moved for the introduction by means of a device and in such a way that additive is dosed exactly in relation to the volume flow of the medium and that a pulsating stream is injected into the medium flowing past, by means of at least one well-aimed nozzle opening. The additives are dosed by means of a pressure that can be adjusted variable, pulse width and pulse frequency. The desired homogenous distribution is obtained by the penetrating injection jet during compounding for instance.

U.S. Pat. No. 4,474,717 by HENDRY JAMES W dated 1982 an injection of spatially predetermine position is claimed:

Injection of a small portion of plastics without introducing inert gas (preloading) followed by sectional introduction of inert gas using frequencies from 4 to 100 cycle per second having a pressure of 300-1500 psi (2 to 10 MPa) into the continuous passing plastic material. The result is a multi layered inside foamed structure.

The submitted invention expands this method by applying injection technology used in the combustion engine technology. Reaching a more intensive penetration by higher pressure (40 to 200 MPa), higher frequency (100 to 1000 hz) and more exact dosing by controlled width of the pulses, frequency of the pulses and regulation of pressure using this technology.

Suggested design of nozzle and channels according to hydro-mechanical principles application for metal, bilk material and high viscous melts can be achieved.

The invention relates to a method for introducing additives into flowing medium by exact dosing and homogenous distribution. The following application, processes and devices coming to an economical realization:

Introduction, dosing and homogenous distribution of additives as there are hardener, dyes, gas processors, softener, reactant into the melt stream of plastics in:

Extrusion systems for sheets tubes and profiles.

Compounding systems for production and adaptation of plastics.

Injection moulding-, blow molding-, and film casting-systems.

Auxiliary processing-, forming operation-, preform manufacturing-systems.

Introduction, dosing and homogenous distribution of catalyzes, reactants in flowing liquid in chemical, processing systems as well as for instance distillation-water-treatment-refinery-systems.

Introducing, dosing and homogenous distribution of bleaching agents, solvents into the circuit of pulp- and ground wood-systems.

Introducing, dosing and homogenous distribution into alloys and metallurgical additives as well as gas processors into the metal melt flow of die casting, profile casting and continuos casting systems.

Introducing, dosing and homogenous distribution of additives and flavor agents for pelletizing-, dough- and noodle processing-systems in the nutrition industry.

Introducing, dosing and homogenous distribution of fuel into combustion systems.

Introducing, dosing and homogenous distribution of dyes and solvents in airless- and spraying systems.

Introducing, dosing and homogenous distribution of additives into fluidised material like bulk and powder material, granules, pellets in plants operating fluidized bed and whirl sintering installations.

DESCRIPTION OF THE INVENTION

The basic new idea of the submitted method for introducing additives consist of obtaining intensive atomizing, mixing and deep penetrating of additives into the medium stream by using high kinetic energy of the additives and exact timed pulsing and exact pulse width using appropriate injectors.

The exact dosing of the additives is obtained by regulation of the operation parameters of introduction for instance pressure, frequency, pulsing width a.

The state of the art of combustion engines using the “common rail” injection technology. The flexibility of this system by modifying the operation parameters is the highlight of this technology in comparison to the former used mechanical operated injection methods as there is injection nozzle ans.

The common rail is loaded with fuel being pressurized up to 200 MPa and supplies the injector with this constant pressure. Electronic controller activating solenoid and piezo-operated electro-hydraulic servo-valves to move the nozzle needle by push rods with high precision. According to this technology exact dosing and homogenous distribution will be obtained.

The application and further development of this injection technology is subject to utilize this improved technology for further applications as mention before.

Furthermore detailed design and configuring of nozzles, nozzle-needles, the arrangement of orifices in position and shape as well as arrangement of injectors are subject of this invention.

State of the Art Concerning Methods for Introducing Additives

The following devices and methods are subject of previous solutions: EP161614 WOLTON FRANK 1985 showing a device for injection of certain amount of medium into the fluid stream. The adding of the additives happens by a charging pump which is activated by the flowing medium. An energetic mixing is not possible because of the small pressure difference.

The device of adding additives into a liquid stream of high viscosity has been introduced in U.S. Pat. No. 5,913,324 SIGNER ARNO 1997.

By diaphragm the high shear forces of the medium with high viscosity the mixing takes place. A dosing is happening in the side stream and independent of the main stream.

A device of adding additives after the plastisicing unit is shown in

EP0432336 CLOUP PHILLIP 1991.

For the adding of additives after the plastisicing unit the following methods are known.

WO89053226 HETTINGA SIEBOLT 1988

Blowing in of air

U.S. Pat. No. 4,931,236 HETTINGA SIEBOLT 1989

Spraying in of air/gas after the plasticising to achieve hose with foam layer.

DE1948454 BAYER 1971

Injection of chemical gas producer after plastisicing unit.

A mixing by energetic injection jet stream and pulsing dosing is not subject of the last named inventions.

A nozzle for application of glue by pulsation is shown in U.S. Pat. No. 5,934,521 KOIKE KATSUHIKO 1998.

The nozzle-needle is activated by a pneumatic cylinder up and down, so that glue pours out in pulsing way. A mixing with a flowing medium passing by is not on purpose.

The pulsing adding of liquid and gas is state of the art in burner-, airless jet- and spraying-systems (atomizers).

The submitted invention is demarcating from these application by higher pressure of the liquid than 40 MPa and high energetic atomizing.

This pressure is not possible with the nozzles used by now. Only by electrical activated hydraulic servo valves in common rail technology these pulsation can be realized.

Description and Economical Benefit of the Present Invention.

Introduction into the Plastic Melt Stream:

The introduction happens after the plastisicing unit.

This is for many processes listed below of advantage.

Recruiting material of different properties out of one plastisicing unit.

For Injection moulding systems predetermined properties like porosity, coloring are possible by one process step by variable introduction. Only multi-component injection moulding machines can do today.

For extruder systems profiles will be extruded with different components at predetermined sections can be foamed by diverting the plastic melt stream and introducing gas creators in one side stream by an injector so that this melt stream will expand an can be joined together with the material of the main stream.

Plastics for sheet and tube extruders can be introduced with dyes, gas processors, softener after the extruder and therefore a fast change of the material properties is possible what leads to economical flexibility in the production.

Pelletizing systems in the nutrition can be modified by introducing flavors and additives after the extruder by injectors, so that the material does not have to go through all the screw total length.

Chemical and process-technological systems like distillation-water-treatment plants and oil refineries.

The introduction and dosing and the homogenous distribution of bleaching agents, solvents in circuits of cellulose-, pulp and mechanical wood pulp happens according to the state of art by dosing units with subsequent mixing.

High shear forces are needed for the efficient mixing.

Any modification of the operation parameters as there is:

Change of amount of additives or

changing of color chemical additives

will have only an effect after completing a total running through of one plastisicing circuit.

Method of Introducing Additives

Exact Dosing and Homogenous Distribution

DESCRIPTION

The present invention relates to introducing additives for instance gas processors into the melt stream of plastics or low melting metals.

The advantage of this process is the application of light weight structures at locations of a part where it is demanded. The gas processing substance for expanding the matrix material is introduced in spatially predetermined positions. Various operation modes and combination of these can be obtained firstly by pressure differences between melt and gas processing substances and secondly by the frequency of pulsation and thirdly by the shape of the nozzle reaching into the melt channel:

Creation of Foam:

Using high frequent pulsation and therefore atomizing at high pressure difference and advantageous at counterflow and subsequent high acceleration of the melt by variable sections of the melt channel. The difference of the speed of melt and additive is selected of high value.

Macro-Hollow Cavities:

The introduction happens by drop shaped dosing of the melt flow at low frequency of the pulsation and only small pressure difference in flow direction and essentially laminar streaming conditions of gas processors and melt.

Continuos Introduction:

Continuos introduction of a string of gas processors at nearly adequate flow speed of the passing medium. Small pressure difference is of advantage.

An apparatus for injection molding of compound parts with charger, which are connected to a pump which is compressing chemical blowing agent has been published in DE1948454 by BAYER 1971 to achieve a spatially predetermined foaming. Because of the insufficient mixing and dosing the proposed foam quality cannot be reached.

The present invention is demarcating from the above apparatus by using injectors (combination of valve and nozzle) and pulsing injection and optional using a continuously pressurized pipeline “common rail” and hydro-electrical activated valves. Because of the shaping of nozzles and channels according to hydrodynamic principles as well as regulated pressure the apparatus is different.

The solenoid is activated by electrical supply and optionally controlled by generating a arbitrary wave generator.

This leads to operation mode like atomizing, dotation and continues string.

The selection of pressure difference and frequency of pulsation leads to a predetermined introduction of gas processors into the melt.

The exact dosing and pressure regulation leads to a targeted dotation of drops into the melt resulting in a subsequent macro hollow cavity expansion.

The apparatus for introduction of gas creating substances into the highly pressurized melt consists of a nozzle in immediate connection with servo-valve, or consists of a pump-nozzle system with a non-return-valve combination.

Especially the injection technology of combustion engineering reached a high state of art concerning the exact repeatability due to the demand of strict exhaust specification.

The State of the Art:

A “fuel-injection valves for internal combustion engines” shown in DE2028442, 1970 by DAIMLER BENZ.

The hydraulic activation of the valve push rod is regulated by a three way valve.

An “Injection device” with hydroelectric activation was invented by PEUQUEOT in FR2145081 in 1971.

The valve is pushed by a continues hydraulic pressure and released by a controlled pressure loss on the backside of the push rod.

In U.S. Pat. No. 3,990,422 at 1973 by BENDIX CORP the control of the hydroelectric activation has been improved by using a two circuit hydraulic system.

The present injectors showing features, being necessary to comply with the demanded application specification. These are: pressure regulation, elecro-hydraulic activation by a push rod valve and pressure controlled by a sphere valve at the high pressure circuit, which is necessary to reach the high frequent pulsation and having the high pressure available at the nozzle needle immediately at the valve seat by a common rail system, which makes the accuracy independent of pressure and velocity differences between the gas creating substances and the melt.

The present invention relates to this high pressure technology to be adapted for the special condition of the introduction into the melt.

The high pressure for injectors in combustion engines is needed for atomizing and distribution of the fuel in the combustion zone. The high pressure for injectors in melt introduction processes is needed to overcome the high melt pressure of about 100 to 140 MPa. Pressure of about 200 MPa can be reached by the available injectors with common rail. The continuos supply and the activation of the valves are solved with high reliability today.

An essential presupposition for running the injectors is the lubrication by the fuel. Since gas creating substances (water, alcohol, liquid gas) do not have substantial lubrication effect.

The basic idea of the present invention is the usage of two circuits applied to the standard injectors available in the market making additional measures.

The Patent JP 8170569 by NIPPON SOKEN 1994 is showing a version of injectors for diesel engines by using a high pressurized circuit for injection and a low pressurized circuit for the servo hydraulic system.

The present injector reaches by separation of the hydro-electrical activation of the push rod of the valve by using standard hydraulic oil and.

The introduction of gas creating substances happens with a slightly lower pressure (different to the JP 8170569) because of non return lock pressure to prevent penetration of melt into the injector.

Only the needle and seat of the valve get in touch with the non lubrication medium. Since these parts can be made of sintered highly wear resistant and easy changeable. The electro-hydraulic servo circuit is not effected because of the separate circuit.

Further alternative solution for the injector are:

Pump nozzle system with a combination of high pressure piston and spherical valves. An electric activated swing system attached to a pump piston.

Limits for the stroke and positioning of the inlet valve as known for airless spraying systems can be used as well.

In some application it is of advantage to have small pressure difference between the introduced material and the melt. For this the above solution can be used.

The regulation and control of the introduction process having the following features:

Optional the hydraulic circuit can be separated from the gas creating substances to be introduced. The pressure p ₁of the medium to be introduced and the pressure p₂of the hydraulic system are regulated by a pressure limit valve.

The controller regulating the pressure depending on the melt p ₃, for the hydraulic system circuit as well as the injection pressure of the introduced medium.

The injector is activated by solenoid or piezo actuator. The regulation is controlled by a “Arbitrary Wave Form Generator”.

Furthermore the specification of hydraulic, nozzles, injectors and melt channel are described below.

The hydraulic for continuos production for instance extrusion, continues casting And for part production by injection moulding and die casting are prescribed.

The system for continuos production is used for extruders. Continuos charging and multiple injector assembly is preferred.

The system for part production is used in injection moulding and die casting systems. Because of the interruption after the injection a simple solution using a pressure multiplier double cylinder is offered for injection moulding systems.

Thy hydraulic system of the existing machine having usual a pressure of 26 MPa, which can be used to bring high pressure by a pressure multiplying system. While plastifacation takes place the pressure multiplier for the hydraulic system as well as for the introducing system is loaded with hydraulic oil and gas creating substance respectively.

For the dotation of the melt with concrete size and spatially predetermined position it is necessary to achieve a constant pressure difference while injection takes place. To high pressure difference leads to the destroying of the melt. The ramping of the pressure is shown in FIG. 9. The injection pressure increases till the nominal pressure while injection operation.

During the injection the gas creating medium must be introduced by a higher pressure than the melt. The velocity of the melt in the gate of the mould has to be equivalent to the introduction speed of the gas creating medium.

For reaching this feature an exact pressure regulation with electrical pressure limit and a precise activation of the hydroelectric valves is necessary. The shaping of the valve, valve seat and the smooth configuration of the melt channel according to hydrodynamic principles is important for repeatable dotation of the melt. The injectors of the “common rail technology” have the capability to fulfill these features.

The regulation of the solenoid takes place by controlling with “Arbitrary Wave Form Generator”, opening and locking can be optimized by this system.

Furthermore the shape of nozzle and melt channel is described.

Method of Introducing Additives

Exact Dosing and Homogenous Distribution.

The present process relates to the modification of the properties (compounding) of an origin extruded material by divertion of the main stream into a side stream and introducing additives into this side stream by dosing, mixing and distribution of the original material.

The kind of additives determine the properties of the plastic material of the melt.

These additives are for instance additional components as there are hardener, dyes, gas processors, softener, filler and reinforcements.

This process can be applied to inside melt channels of mould for extrusion as well as for injection moulding systems, by means of using at least two diverted streams of melt to reach different properties of the plastic material.

Profiles produced by this process having different properties of the material on spatially predetermined positions.

This method saves an additional extruder to produce the additional material component.

The essential advantage is, that based on the same origin material the waste disposal is not necessary, because based on the same material the recycling results in a unique material.

The additives are introduced by nozzle, injector, charging tube, mixing head, porous sinter metal, sliding pump, charger and spraying system.

The following concrete application for production of profiles are subsequently shown for instance:

PVC Window Profiles.

Sections of the profile close to the outside or inside can be insulated with the present process by using foam filling at the concerned chambers.

The calipers as used for the known multiple chamber systems will be adapted with inside channels and with the present described devices. From the main melt stream, diverted material comes to the channel duct within the caliber in which by means of a metering regulation (as there are valve, throttle) the melt is fed to the device for introduction of the additives. Subsequently devices for mixing and homogenizing are placed in the channel to complete the compounding process. Using PVC for the window profile the additive will be physical gas creators like water, carbondioxyd, alcohol, glycerin ans.

The pressure ramping in the melt duct is decreasing, for the additives giving additional gas volume. For expansion of the material a conical zone is configured according to the volume increase or according to the velocity increase the additional volume comes to a expansion zone (conical increasing outlet) so that the compounded material is lead to the outside solid PVC profile shells and can be homogenous and adhesive bound together.

The advantage of the profiles with multi components comes by the cost effective production and the better properties of the material for heat and sound insulation (low pressure within the foam cells and therefore lower heat transfer rates) and less cost for recycling of the waste material.

As variation the additives can be introduced by singular dotation and leading to a profile with honeycomb shaped cellular structures of high strength. These structures replacing the necessary stiffener profiles.

Window profiles out of Polyolefinen: as described above but using Polypropylen PP or Polyethylen PE, HDPE an

Claddings or Panel Shaped Coverings for Outside or Inside Walls.

More simpler than described above the total extruded profile with foam core and large cell structure can be obtained by one diverted material stream from the main stream to be compounded within the center of the profile. The subsequent process of calibrating and cooling remains the same as before.

The so obtained profiles can be used for inside cladding, mobile walls and having high stiffness by using large cell striker.

Tubes from PVC, PO

Because of suitable introduction of gas creating and/or fillers, or reinforcement to the melt stream into the spatially predetermined locations, as there are intermediate layer, outside layers ans. the multi component tube can be produced with simple measures. The device for compounding is attached in between the flanges of extruder and mould and is supplied by the channels of the mould to modify the properties of the material.

Another production process with excellent mixing of the melt consists of introducing the additives before the cellular pump.

Another improvement can be installed by attaching a mixer or dynamic mixing head for homogenous compounding.

Coloring of the Outside Layers of the Profiles.

The introduction of dyes into the diverted melt channel makes it possible to come to a fats changeable coloring process. Most economical, because the expensive dyes are only applied on the outside and no losses of material happen by changing of the color, since the extruder has not to be emptied completely therefore. The change of the color come into force immediately.

Further possibilities for cost reduction can be achieved by bringing the coloring to the outside layers only.

Production of Sheets, Insulation Sheet Material and Compound Sheets.

For system having a large working width the additives can be introduced into the center layer of the extruded sheet, or diverted to a melt channel similar as described before for the device as implemented into the calipers having the total width of the sheet.

Apparatus for Adding Up a Extrusion System for Multi Component Process.

The apparatus will be attached in between the flanges of the extruder and the mould. Following elements are included:

Inlet cones with diverting device for the melt channels.

Pressure and volume metering system.

Device for introduction of the additives optional consisting of nozzle, injector, charging pipe, mixing head, porous sinter metal, sliding pump, charger or spraying system.

The mixer consist of static mixer, for instance with shafts, pins, diaphragms, helical zones.

The expansion zone consists of variable sections, especially for foam components or macro cellular structures in the melt stream.

Apparatus for Dotation and Mixing of Additives into Liquid Medium by Using Valve Cone Orifice or Pocket Hole Orifice, Especially Hot Runner Valve.

The invention relates to a multifunctional mixing and dosing head, consisting of a nozzle cone and a nozzle needle, in which the volume flow is metered or blocking the outside flowing medium by the position of the outside nozzle needle and consisting of a nozzle cone and a nozzle needle, in which the volume flow is metered or blocking the inside flowing medium by the position of the inside nozzle needle.

This combination of valve, nozzle and injector leads to a economical mixing and dosing directly on the needle top of the concentric double cone.

The invention also relates to a hot runner valve, having an injector, for introducing the additives into the outer flowing medium, instead of the valve needle.

Several combination of mixing and dosing head are mentioned, especially the attachment in plastisicing unit, extruders, melt channel and the subsequent attachment of statical mixer systems.

The economical benefit consists of the spatially predetermined location of the dotation and the excellent mixing and the exact dosing according to the mixing ratio.

Application for this hot runner valve with integrated mixing head for introducing additives like dyes, hardener, softener, gas processors ans. directly into the plastic melt and immediately before the gate of the mould.

Besides the several known 2 component hot runner valves the present suggested solution is having following features:

The application of the concentric positioned nozzle needles within the nozzle needle.

In EP 0310 914 from 1987 “process for injection moulding” (BATTENFELD) a concentric positioned nozzle needle are shown in FIGS. G.1 to 6.5.

The present apparatus is demarcating from the above by using a spatially predetermined dosing of the melt while in EP 0310914 only each of the two media is switched to the mould, while the present apparatus can achieve any mixing ratio in between by using the introduction of the additives by pulsation.

In U.S. Pat. No. 4,657,496 from 1987 by HUSKY

A hot runner valve for 2 components is presented with concentric positioned charging tube. By the cavities (9) and (6) within the nozzle needle, depending on the position either the one or the other component is blocked or open respectively. The concentric shaping of the inside located nozzle makes it possible to regulate the dosing by moving the outside nozzle needle. Which is controlled by the inner or outer nozzle.

A mixing or a fast pulsing introduction as shown by the present apparatus is not subject of the U.S. Pat. No. 4,657,496 Patents.

The target of the present invention is not only to introduce at least two media in a concentric manner, but also achieve a mixing i.e. to dotate the outer medium with the inner medium.

In U.S. Pat. No. 5,286,184 a variation of the concentric nozzle is published, which differs to U.S. Pat. No. 4,657,496 the activation of the hollow shaped nozzle needle. Also in this case there is a concentric introduction, but no mixing or dotation is the target.

The nozzle needle is activated by a push rod within the boring of the nozzle needle and is regulated by a servo-mechanic.

To reach a spatially predetermined position by the dotation and/or dosing and excellent mixing the usage of a valve cone orifice VCO and a CDI injectors, as it is used in the combustion engines of advantage.

The activation of the injector is known by a hydraulic piston but also can use for the servo-mechanics for instance solenoid, piezo actuator hydraulic servo.

DESCRIPTION OF THE FIGURES

Indexing of reference numbers:

1. Nozzle needle precisely moved

2. Nozzle body 30

3. Nozzle needle seat

4. Plane plurality of orifice arrangement

5. Cavity at valve cone orifice VCO

6. Radial plurality of orifice arrangement 28. Combustion chamber

7. Axial boring in nozzle body 35 29. Combustion zone

8. Cavity at valve sack orifice 30. Inner rod (caliber) of extrusion mould

9. High pressure pump 31. Section of extruded profile

10. Channel of streaming medium 32. Inner rod (caliber) for hollow section

11. Injector 33. Foamed inner section

12. High pressure piping 40 34. Hollow section

13. Leakage backflow piping 35. Extruded profile

14. Container of additives 36. Cascade shaped injection

15. Common rail (communication system) 37. Radial plurality of orifice arrangement for

16. Cellular pump extrusion

17. Streaming medium 45 38. Core of the mould

18. Injection spray stream 39. Jet streaming combustion air

19. Plastisicing barrel 40. Screw of plastisicing unit

20. Dosing chamber of barrel of injection 41. Expansion zone in the extrusion mould, moulding machines preferable situated in the inner rod of the

21. Nozzle of plastisicing barrel 50 mould

22. Mould

23. Hot runner system

24. Non-return-valve

25. Airless spraying system

26. Compressor

27. Combustion air piping

28. Combustion chamber

29. Combustion zone

30. Inner rod (caliber) of extrusion mould

31. Section of extruded profile

32. Inner rod (caliber) for hollow section

33. Foamed inner section

34. Hollow section

35. Extruded profile

36. Cascade shaped injection

37. Radial plurality of orifice arrangement for extrusion

38. Core of the mould

39. Jet streaming combustion air

40. Screw of plastisicing unit

41. Expansion zone in the extrusion mould, preferable situated in the inner rod of the mould

51 Mould for production of profiles by extrusion

52 Melt stream, feeding of melt from extruder to the mould

53 Caliber inside the melt stream section, implementation for the mould to conduct the melt stream, particular with an integrated melt channel.

54 Injector, nozzle for introducing of additives into the separately arranged melt channel.

55 Introduction of additives

55 a Introduction in flow direction

55 b Introduction in counter flow

56 Outlet section of separately arranged melt channel.

57 Caliber inner rod for forming a hollow section and hollow profile.

58 Melt channel with original shaped extruded profile and the corresponding section.

59 High pressure pump for additives.

60 Zone of expansion for the introduced gas creating additives.

61 Adjustable section for controlled outflow, chicane for mixing

62 Adjustable section for controlled inflow.

63 Pressure sensoring cell for the separately arranged melt stream as indicator.

ΓCaliber inner rod with melt channel and inlet opening.

65 Tubular inlet section for multiple shell arrangement for extrusion profiles.

66 Central inlet opening for the inner shell of the extrusion profile.

67 Intersecting melt duct, passing through main melt stream

68 Flange of the mould

69 Flange of the extruder

70 Intermediate add up equipment

71 Extension of the melt stream channel

72 Intersection through the melt stream channel

81. Melt medium nozzle needle outside

82. Additive nozzle needle inside 40

83. Coaxial conical needle seat

84. Bolt in boring to activate the additive nozzle needle

85. Supply of additives to the boring

86. Details of mixing and dosing device 45

87. Valve cone orifice, Pocket hole orifice

88. Common rail injector (CDI injector)

89. Supply channel for melt stream

90. Activator piston by hydraulics

91. Supply of the additives

92. Introduction of additives to the melt

93. Servo-mechanics for instance electro/hydraulic, piezo/hydraulic

94. Hotrunner Nozzle seat

95. Injection Molding nozzle seat

96. Injection Molding plastisicing nozzle

97. Extrusion nozzle seat

98. Supply device

99. Melt channel for extruders

100. Statical mixer

101 Feeding device for gas creators 40

102 Pressure controller for gas C. p1

103 Circuit for gas creator substance

104 Hydraulic circuit for activation

105 Feeding device for hydraulic circuit

106 Pressure control for hydraulic c. p2 45

107 Tank for hydraulic oil

108 Spheres for valve hydraulics

109 Solenoid or piezo activator device

110 Hydraulic activation of the valve

111 Back pressure, seal 50

112 Valve for the injector

113 Nozzle of injector

114 Gate of the melt stream

115 Pressure sensor-cell in melt stream

116 Adapting device between the 55 runner

117 Introduction of additives to the melt

118 Heaterband of the adapting device

119 Pressure control for additives p3

120 Arbitrary Wave Forn Generator 60

121 Pressure controller for additives

122 Controller

123 Interface to injection moulding machine, extruder, die-casting

124 Pump-nozzle combination 65

125 Leakage piping

126 Supply piping for hydraulic flow

127 Anchor for solenoid activation

128 Injector continuous introducing of additives

129

Throttle valve

70

130 Valve push rod

131 Spring for clamping

132 Feeder piping for gas creator

133 Additional channel for 2 nd medium

134 Stopping device f. stroke 75 limitation

135 Pump push rod

136 Feeding pipeline valve

137 Feeding pipeline for sphere valve

138 Reverse motion spring

139 Backpressure valve on melt end

140 Leakage pipeline

141 Shrinkage of sphere seat

142 Hydraulic system of basic machine

143 Pressure multiplier piston additive

144 Pressure multiplier piston

145 Axis for force in MPa

146 P1 pressure of additive

147 P2 pressure of hydraulic

148 P3 pressure of melt

149 P5 pressure on control piston

150 Axis of time

151 Current supply to solenoid

152 Center line

153 Trapezoid wave shape

154 Triangle wave shape

155 Half sinus wave

156 Full sinus wave

157 Periodic wave form

158 Unsymmetrical full sinus wave

159 Heaterband for injector

160 Injector

161 Introduction in flow direction

162 Adaptation to the mould

163 Spraying in melt flow I counter melt

164 Volume enlargement after

165 Nozzle body

166 Slot shaped nozzle

167 Radial shaped nozzle borings

168 Valve cone orifice

169 Enlarged Laval channel

170 Nozzle needle open

171 Channel of nozzle

172 Valve cone orifice nozzle channel

173 Conical nozzle needle, axial spray

DESCRIPTION OF THE FIGURES

In FIGS. 1 and 2 nozzles and nozzle needles and needle seats are shown. The subsequent FIGS. [0326] 3 to 17 showing samples for the application of the present method of introduction with exact dosing and homogenous distribution.
FIG. 1 showing a valve cone orifice VCO nozzle tip. With ([0327] 1) the nozzle needle closing the needle seat (3) located in the nozzle body (2). The small volume of the front chamber (5) is the target of the VCO. The orifices (4) are inclined about 80° to the axis as used in combustion engines. Other orifices (6) shown on the right side of the axis having a stepwise inclinations of 0° to 75° inclined to the axis.
In FIG. 2 a pocket hole orifice is shown. The larger front chamber ([0328] 8) of the nozzle gives a larger volume of free drops, by means an inexact dosing. The larger chamber gives the possibility of several radial arranged orifices (6) as well as an axial positioned orifice (7).
In FIG. 3 an arrangement of a dosing and mixing arrangement for a flowing medium in a tube ([0329] 10) is drawn. 5 injectors (11) reaching into the tube. The injectors are connected to a high pressure pipeline (12) containing the additive. The tank (14), the high pressure pump (9) and the common rail (15) and the leakage pipe (13).
In FIG. 4 an arrangement of FIG. 3 is shown from the top view for a extrusion system. The dosing and mixing unit is positioned in flow direction between the cellular pump ([0330] 16) the mixing tube (10) and mixer (10) and the mould (22).
FIG. 5 showing a sectional view of the tube ([0331] 10) enlarged. The 5 nozzle tips (2) are in a radial 72° pattern arranged. Each nozzle top is having 7 orifices positioned in an angle of 75°, 50°, 25° and 0° ans. The jet of the injection (18) giving a complete covering the section of the medium (17). The length of the jet stream is determined by the diameter of the orifice and is usual between 0,11 mm and 0,14 mm.
The FIG. 6 shows a mould for an extruder producing a cylindrical profile. Two of the several arranged injectors ([0332] 11) are shown in the section. The additives (18) are introduced according to the velocity of the medium (17) in the flow direction.
In FIG. 7 the detail of the nozzle arrangement is drawn. The nozzle bodies ([0333] 2) having at least one orifice (4) in the direction of the melt channel. The jet stream is directed to bring the additives not wall sides (10), but into the core (38) of the stream.
In FIG. 8 an application for a single injector is arranged which is inclined about 45° to the tube axis ([0334] 10). The orifice (4) is inclined in a flat slope angle to the medium flow i.e. the orifice is positioned about 400 out of the axis of the injector. The pulsing introduction is giving a cascade distribution shown in FIG. 9.
FIG. 10 gives applications for injection moulding systems. Similar to FIGS. 8 and 9, two injectors ([0335] 11) are introducing the with a light slope in direction of the axis of the nozzle tip (21) of the plastisicing unit. The location of the injector is after the screw tip (40) but within the front chamber (20) of the barrel (19).
For further excellent mixing for instance of dyes of advantage. This arrangement also can be placed within screw sectors within the plastisicing arrangement. [0336]
For accurate dosing with less mixing the arrangement of FIG. 11 rakes place. The introduction happens in the center hole of the plastisicing nozzle tip ([0337] 21). This is used for application with hardener and softener (minimum leakage).
In FIG. 12 the introduction happens by the injector ([0338] 11) immediately after the mould gate at the inlet of the mould (22). The advantage of a hot runner system (23) is evident.
The Mixture of medium and additives is not depending on the plastisicing unit ([0339] 19) but determined by the introduction of additives i.e. flexible and variable.
FIG. 13 is showing an airless jet stream ([0340] 25). The flowing medium (39) is the streaming side air. The additive is dyes (18). The pulsation determines the coloring conditions.
The nozzle arrangement is shown in FIG. 14. At least one orifice ([0341] 4) in the nozzle body (2) is directed near the axis and determines the spraying structure (18).
In FIG. 15 the dosing and mixing arrangement is shown for a combustion system. The nozzle body ([0342] 2) is reaching into the combustion chamber (27) and is limited by the casing (28) of the burner zone. The combustion air is compressed by a blower (26) and the atomizing of the fuel using the standard arrangement of orifices located on a cone.
The injection jet stream ([0343] 18) results a accurate dosing and mixing of the perfect combustion. (29).
In FIG. 16[0344] a and b the application of a mould for an extruder production of profiles—for instance of window profiles—is arranged. The dosing and mixing having the purpose do modify material diverted from the main stream of the melt for example with gas processors. The section shape is shown in FIG. 16 b. The injector (11) reaching into the side channel (30). The different material streams (31) are separated by inlet channels, calipers (32). The melt stream (17) is introduced (18) by additives and is creating foam in the side stream which is transported to the chambers (33) and (34). Chambers with solid calipers creating hollow profile space as usual.
In FIG. 17[0345] a and b the introduction of additives (18) by pulsation into the side channel is shown. The arrangement is also for extrusion systems as in FIG. 16 as well as for pelletizing and continuous casting with mixing zone (10) applicable.
FIG. 17[0346] a showing the tube section (30) and the single tube (10).
FIG. 17[0347] b showing the lateral section of the tube (30/10).
The nozzle body ([0348] 2) is having 7 radial arranged orifices (4) and giving full coverage of the material section (17) by the jet streams (18) for dosing and mixing.
A sequence of several jet streams ([0349] 36) respectively (37) introduced in flow direction are shown in 17 b.
In FIG. 18 the total apparatus for injectors of standard design is given in the layout. [0350]
The using of pumps ([0351] 101) and (105) enable the application to be used in a continuos operation (extrusion). The circuit for the additives (103) is separated from the circuit of the hydraulic oil of the servo (104). The pressure of the circuits is regulated by a electrical activated presser limit valve (102, 106). The valve (112) is released by a electro-hydraulic mechanics. This mechanics consists of a solenoid (109) a spherical valve (108) and the push rod connected to the high pressure piston (110). The controller (122) is regulating the electro-hydraulic mechanics according to the information (120) given by the operation data as there is injection time/extrusion data (123) according to the pressure sensor in the melt (115) of the pressure of the additive circuit (102) and the pressure of the hydraulic oil of the servo (106).
The arbitrary wave form generator ([0352] 120) creates the opening current for the electro mechanism (112). The introduction of the gas processors (117) into the melt stream (114) happens in the interface (116) part after the extruder tip (160) by a nozzle (113) reaching into the channel. For heating a Heaterband (159) is located around the nozzle (113).
FIG. 19 showing an standard injector. This version showing a pocket hole valve ([0353] 113) with a small front chamber.
The valve seat ([0354] 112) is locking the nozzle from the continuos pressurized circuit. The push spring (131) increases the force resulting of the difference of force on the nozzle needle (112) and the hydraulic pressing (110).
The opening is activated by the solenoid ([0355] 109) which releases the sphere of the valve (108) and hydraulic oil of the servo is streaming out of the high pressure chamber (110).
FIG. 20 showing an injector of the state of art. The essential features can be already recognized. The version with the electro-hydraulic activation is extended by throttle ([0356] 129) and anchor(127) and double chamber.
Standard Injectors having separate inlets ([0357] 126) for the servo supply and the injection supply.
FIG. 21 gives a section of a modification of a standard “common rail injector”. The already available two supply borings are attached to a special fitting. [0358]
FIG. 22 showing the modification of a standard “common rail injector” with a second boring. The supply ([0359] 132) of the hydraulic servo circuit is blocked by a pin.
Additional supply is given by a boring ([0360] 133) and a second fitting (126) for the servo circuit.
FIG. 23 showing a pump-nozzle configuration in principle, by means the high pressure chamber is close to the nozzle located. The medium of the additive is supplied through a boring in the push rod ([0361] 135). And the pressurizing is effected by a inlet- (137) and an outlet-valve (139). The penetration of the melt into the injector is prevented by a sphere (137) which is pressed by a non-return-spring (138) into the valve seat.
The push rod ([0362] 135) is activated by a magnetic swing system (127). By stroke limit (134) the size of the pulsation is determined. The line for leakage (140) returns the overflowing medium.
FIG. 24 is showing the principle of an airless spraying state of the art system, applied for the present application by using a valve sphere ([0363] 139) within the nozzle. The advantage of a small front chamber can be reached by a overlapping (141) of the sphere valve. (134,135,140) as shown in FIG. 23.
FIG. 25 is showing a hydraulic system for part production for instance for injection moulding and die casting systems. The operation of the injector is having a twin circuit system. The pressure multiplier is connected to the basic hydraulic system of the machine ([0364] 142). While processing the part there is time to load the system for injection. The pressure multiplier cylinder for the additive (143) and for the servo hydraulic oil (144) are pressurized being regulated by the pressure limit valve (142) during the melt injection having the pressure p₄Subsequently the chambers of the cylinders are refilled by pumps (101) for the additive and pumps (105) for the hydraulic oil.
FIG. 26 showing the features of the pressure ramping y-axis in MPa ([0365] 145) over the duration for the present processing.
The melt pressure p[0366] ₃is shown by the curve (148), The pressure of the additive p₁is shown by curve (146), the pressure of the servo hydraulic p₂shown with the line (147).The electric potential (153) to activate the electro-hydraulic regulation is shown by the curve (149). Various wave forms are for triangle (154) for half sinus waves (155) for different frequencies and full sinus wave form (156) and the same with different frequencies and phases (157) full sinus form in.
Created for different phases and ([0367] 158) unsymmetrical wave forms by an arbitrary wave form generator.
FIGS. 27, 28 and [0368] 29 showing several melt channels.
FIG. 27 a parallel melt channel ([0369] 114) in flow direction positioned orifice having an interface part (116) between mould (162) and nozzle tip (160) of the barrel. This arrangement is applicable for dotation with drops (161) into the melt stream (114).
FIG. 28 a radial multiple orifice ([0370] 163) in flow and counterflow position for excellent mixing of the additives with the melt in a enlarged melt channel (114) which causes additional mixing by change of velocity.
FIG. 29 a continues string introduction ([0371] 164) into the melt channel. These method is able to process axial hollow cavities for extruded profiles.
FIGS. 30,31 and [0372] 32 a nozzle with various orifices.
FIG. 30 state of the art [0373]
[0374] 30 a VCO valve cone orifice
[0375] 30 b radial multiple orifices
[0376] 30 c pocket hole orifices
FIG. 31 a nozzle for flow and counterflow introduction. [0377]
For introduction of additives as drops into the melt the nozzle is design according to hydrodynamic principles. [0378]
For preventing atomizing sharp edges have to be avoided. [0379]
The channel profile having smooth profiles in valve cone ([0380] 17 z 0) and at the nozzle profiles (171).
FIG. 32 a nozzle introducing drops sidewise in flow direction. [0381]
FIG. 33 a nozzle for atomizing in the conical seat ([0382] 172) and plane seat (173) rectangular to the flow direction.
FIG. 34 shows a detail of the device for compounding a melt stream. This version is implemented in calipers ([0383] 53) of profile moulds. (51) or for array assembly for moulds to produce sheets.
The section is showing detail of FIGS. 16[0384] a and b.
The view showing the material flow from right to left. [0385]
The caliber ([0386] 53) at the inlet side is conical (64) shaped. The inlet is having a pressure sensor (63) connected to the controller (62) and supplying data it.
The introduction in flow direction ([0387] 55 b) and counterflow (55 a). The advantage of the counterflow is the save introduction of individually closed dotations. The introduction optional by pulsation. For instance chicanes for the melt. The change of velocity leads to shear forces and to additional mixing respectively. The expansion zone (60).
FIG. 35 showing the top view of FIG. 34 the relevant numbers are the same. Note the narrow section in the melt channel. [0388]
In FIGS. 36[0389] a and b the section of the outlet is shown related to the device in FIGS. 34 and 35.
FIG. 36[0390] b showing the inlet in a sectional view.
FIGS. 37[0391] a and 37 b showing the version as it is in FIGS. 33a and 33 b but for simple foamed profiles as there are claddings with insulation integrated, panels and tubes.
Numbers the same as in FIG. 33. [0392]
FIG. 38 a version of melt channel before the distribution chamber of the mould. Two inlet cones ([0393] 64), (65) and the center inlets (66) giving a twin chamber of the melt.
FIG. 39 a version of melt channel design with central inlet of the side channel and a concentrically (twin) introduction of additives and subsequent merging the melt at spatially predetermined locations of the profile. [0394]
The melt channel is crossing the main channel ([0395] 67) in the center of the surrounded flow.
FIG. 40 a showing a rectangular profile, [0396] 40 b circle, tube profile, 40 c elliptic profile, 40 d rounded rectangular profile.
Several profile shapes with multiple components are shown for instance in FIGS. 33, 38, [0397] 39 and 41 being produced as simple tubular profiles.
FIG. 41 sketches a device with a add up for existing extrusion systems and can be modified for multi component operation. ([0398] 68) is the flange of the 69) the flange of the extruder.
([0399] 70) is the interface part for adding up and (71) is the melt channel with through put.
FIG. 42 showing the device in FIG. 41 in detail. [0400]
The device is made out of a disc ([0401] 70) and attached between the flanges (68) and (69).
The disc having the injectors for introduction of the additives as well as diaphragms ([0402] 72) to divert the melt channel. The tube (72) with attached planes for the hollow calipers is shown in principle.
In FIGS. [0403] 43 to 46 hot runner valves for injection moulding systems are shown.
FIG. 44 a present device in comparison of the state of art. [0404]
FIGS. 45A to [0405] 45C the activation of the needle top.
FIGS. 46A to [0406] 46C the above in detail.
FIG. 47 the version with high frequency pulsing (CDI Injector). [0407]
FIG. 48 the integration of CDI Injectors in the hot runner valve. [0408]
FIG. 49 the arrangement of a mixing and dosing head for example in the melt channel of the plastisicing unit of a injection moulding machine or an extruder. [0409]
FIG. 50 showing an arrangement of a twin unit in counterflow used for liquid/liquid mixing as well as for extruders with an subsequent static mixer. [0410]
FIG. 43 showing a device for mixing and dosing and dotation. The inner nozzle needle ([0411] 82) is activated by the adjusting device (93) and is giving the (83) of a pocket hole orifice or a valve cone orifice.
This insert also is part of the outer nozzle needle and shaped to be attached to the ([0412] 90).
The supply of the additive happens by the boring ([0413] 85) and is again attached to the interface (91).
The viscous medium is supplied by the channel ([0414] 89) and coming to between the outer nozzle (81) and the supply tube (94,) for instance a hot runner valve a plastisicing unit or a melt channel of an extruder to the final destination.
Prior Art: showing the version of an inner nozzle needle as a push rod ([0415] 84), as well as the inner nozzle seat, as well as the outer nozzle (94), or both according to the position of the push rod (84) for opening or locking. The outer nozzle needle is moved and regulated according to the supply of the outer medium.
In FIG. 44 the present device is shown and having a nozzle insert ([0416] 83) as shown in the figure as a valve cone (VCO). The orifices of the inner nozzle (83) are completely covered while (82) locked.
The inner substance is supplied between the nozzle needle ([0417] 82) and the valve cone orifice (83) and is introduced in the inlet to the outer.
According to the position of the inner nozzle ([0418] 82) the pulsation, the atomizing of the introduced substance (85) into the outer medium (89).
The conical shaped outer nozzle needle ([0419] 83), being at the same function for the inner nozzle needle is locking the orifices of the nozzle seat of the hot runner (94) Of the plastisicing unit (95) or of the melt channel of an (97), and regulates the opening according to the demanded volume flow and the introduction of the two media (92).
In FIG. 45A the open position for introducing the outer medium is shown. [0420]
The outer nozzle needle ([0421] 81) is open, the inner nozzle (82) is closed.
The substance ([0422] 85) cannot penetrate.
In FIG. 45B the inner nozzle needle ([0423] 82) is open and giving space for the valve cone orifices (83) and the inner substance (85) is introducing to the outer medium (92).
In FIG. 45C the inner- ([0424] 82), as well as the outer nozzle needle (83) is closed.
FIGS. 46A, 46B, [0425] 46C are corresponding to the FIGS. 45A, 45B, 45C but in enlarged details.
FIG. 47 showing the combination of a CDI injector ([0426] 88).
In a nozzle seat as cone valve/pocket hole nozzle ([0427] 87), having the function of the nozzle needle in the needle seat of the melt channel and closing the valve seat of the hot runner valve (94).
The CDI injector is activated by the position device ([0428] 93).
The inner nozzle needle is activated by a solenoid/hydraulic or a piezo/hydraulic servo. [0429]
The supply of the substance happens through the fitting ([0430] 91).
The melt is supplied by the channel ([0431] 89).
FIG. 48 is showing details of FIG. 46 and differs by the melt channel ([0432] 89) attached as a separate insert (87).
FIG. 49 showing the arrangement of a mixing and dosing head ([0433] 95) inside the nozzle tip of the plastisicing unit (96) of an injection moulding system.
The insert ([0434] 87) reaching into the mixing head (95) and the outer nozzle (81) the same time as the insert (87) regulates the flow of the melt (89).
FIG. 50 showing the dosing and mixing head ([0435] 98) in a tube for instance in a tube as liquid/liquid mixer of a melt channel of a extrusion system (99).
The inserts ([0436] 87 a, 87 b) reaching into the conical nozzle seat of the mixer and modifying the outer nozzle needle (81) according to the position of the volume flow of the melt (89).
The supply happens by a charging device ([0437] 97) and into the conical valve seat. The additional mixing by arranging the mixing heads in a counter flow to have counter impact of the media flow.
Optional having this [0438] arrangement 4 media can be mixed together.
Optional a static mixer can be attached subsequent to the mixing and dosing device. [0439]

Claims

1) Method for introducing additives for exact dosing and homogenous distribution into flowing or fluidised media, whereas at least one nozzle with a nozzle needle and said nozzle needle is variable activated with high precision by a device, and the amount of additives is dosed in relation to the volume stream of the medium and said nozzle having at least one orifice and the additive is sprayed into the passing medium through said orifice with high pressure and with pulsation, maintaining high kinetic and pulse energy, reaching a penetration into the medium and a homogenous mixture.

2) Method for introducing fluid additives into flowing or fluidised media according to claim 1 wherein the additives are introduced and distributed by pulsing injection and at least one operating parameter concerning the additive, of the method as there are temperature, pressure, duration of pulses, frequency of pulses and operating parameter concerning the medium as there are temperature, Pressure, mass flow are variable controlled.

3). Method for introducing, for instance injection, atomizing according to claims 1 and 2, of at least one additive in melted, pasties, liquid, dissolved, dispersed, emulated condition, or a combination of this conditions are injected into a medium stream consisting of gas, liquid, melt, paste, plastics, solution, dispersion, emulsion, fluidised bulk material or a combination of this media, wherein the hydro-mechanical blending is carried out by variable pulsing activated injector, and the exact dosing and homogenous mixing is variable controlled by subsequent operation parameters:

Additives:

temperature,

pressure,

duration of pulse,

frequency,

Medium:

temperature,

pressure,

velocity of stream.

4) Method according to claims 1 to 3, wherein additives for instance hardener, dyes, gas producers, softeners are introduced and exactly dosed into plastic melt, metal melt or fluidized material and homogenous mixed.

5) Method according to claim 4, wherein the additives in die casting systems, optionally are introduced by pulsation into the barrel between two section of the plastisicing cylinder, into the front part of the plastisicing cylinder, before the nozzle, into the melt channel after the non-return-valve, into the Hotrunner system, into a side channel of the melt channel, into side channels of mould sectors.

6) Method according to claim 4, wherein the additives in extrusion systems, optional are introduced by pulsation into the barrel between to sections of the extruder plastisicing cylinder, into the barrel front chamber, into the melt channel after the extruder nozzle, after a cellular melt pump, into melt channels of the moulds, before the melt distribution system, into the section before the outlet.

7) Method according to claim 4, wherein additives in plastic injection moulding systems are introduced by pulsation optionally are introduced by pulsation into the barrel between two section of the plastisicing cylinder, into the front part of the plastisicing cylinder, before the nozzle, into the melt channel after the non-return-valve, into the Hotrunner system, into a side channel of the melt channel, into side channels of mould sectors

8) Method according to claims 1 to 3, wherein additives in pelletizing systems are introduced by pulsation into the mass flow optional between two sections of the pellet extruder, into the front chamber of the extruder, before the nozzle, into the mass flow channel after the extruder, in parts of the channels of the mould.

9) Method according to claims 1 to 3, wherein fuel/color are introduced by pulsation in burner/airless spraying-systems are introduced by pulsation into the combustion air stream/spraying stream.

10) Apparatus for introducing of at least one additive in melted, pasties, plastics, fluid, fluid-gas, solved, dispersed, emulated condition, or in combination of said conditions, into a medium stream consisting of liquid, gas, melt, paste, plastics, solvents, dispersents, emulgents, granules, pulp, homogenous material and bulk or combination of this media, wherein at least one variable pulsing activated injector reaches into the medium stream and at least one of the following features are designed:

Injector: number of nozzles Orifice in the nozzle Number Direction Diameter Variable streamline section (Laval) Valve of the nozzle Needle of the nozzle Seat of the needle Blind pocket valve, Valve cone orifice, stream-bending Geometric shape of the needle seat Creation of pressure Pump-nozzle (pulsing) Constant pump common rail Activation of the needle Mechanical Hydraulic One medium (activation and additive is identical) Mechanical valve Electro-magnetically valve Solenoid Piezoelectric Separate medium for hydraulic and additive Electrical Solenoid Piezo electric Streamline section Sectional shape Variable streamline section (Laval) Application of mixing devices

11)Apparatus for introduction of additives according to claim 10 for instance hardener, dyes, gas producers, softener into plastic-metal melt, wherein at least one injection nozzle or injector having at least one orifice of 0,08 to 0,2 mm diameter, designed according to the requirement of depth of penetration of the jet into the melt, the direction of the orifices, seat of nozzle as blind pocket valve for homogenous pressure ramping and equal pressure supply to all orifices or as VCO (valve cone orifice) for having small leakage volume and energetic atomizing, because of the narrow slot between nozzle needle and nozzle seat, optional is the activation of the needle by electro hydraulic system as servo valve driven by solenoid, or by piezoelectric actuator, or pneumatic, hydraulic or by extern magnetic field driven nozzle needle, or by linear drive system.

12) Apparatus according to claims 10 and 11, for injection moulding systems, wherein the injectors are located after the screw (40), optional reaching; into the front plastisicing chamber (20), into the melt channel after the nozzle (21), into the hot runner system (23), or directly before inlet to the mould (22).

13) Apparatus according to claims 10 and 11 for extrusion systems, wherein the injectors are located after the extruder optional reaching; into the melt channel (10) after the cell blade pump (16), into the melt channel before the mould (22) or into the mould between outer (10) and inner (22) caliber.

14) Apparatus according to claims 10 and 11 die casting systems, wherein the injectors are located after the melt extruder, optional reaching into the melt channel after the dosing pump, or into the mould (22). FIGS. 8 and 9.

15) Apparatus according to claims 10 and 11 for burner systems, wherein at least one injector (11) having at least one orifice being located on a cone with an opening angle between 20° and 80° and is reaching the combustion air stream (27) for current streaming.

16) Apparatus according to claims 10 and 11 for airless systems, wherein the injectors (11) having at least one orifice (4) which is about in the direction of the axis, are reaching the current streaming (39).

17) Apparatus according to claims 10 and 11 for extruder systems forming profiles for instance for window profiles, wherein at least one injector (11) is reaching into a side channel (31) of the main melt stream (17), and said side channel is advantageously embedded in a core (32) of the mould, and this channel consists of a conical shaped expansion zone (41). FIGS. 16a and b.

18) Apparatus according to claims 10 and 11 for pelletizing systems, wherein at least one injector (11) reaches into the medium stream (17) and the nozzle body (2) is having at least one orifice (4) and said orifice is positioned rectangular to the flow direction.

19) Device of an apparatus for introduction of additives into melt of plastics or metal according to claims 10 to 18, wherein the injection nozzle (113) is immediately connected to the servo-valve (112) is formed as an injector (128), and connected to, at least one pressure controlled connection (common rail) and said connections optionally are separately configured for the hydraulic servo-circuit (104) and for the additives to be introduced (105) and that the pressure (102) of the said circuits of additives (103) and/or of the servo-hydraulic (104) optionally are controlled by a dynamic presser-valve (102, 106) by a controller (122) in relation to the melt pressure (119) and the hydraulic servo circuit (104) of the injector (128) is optionally activated by solenoid or piezo-actuator (109) and the controller (121) is activating the said injector (128) optional by a arbitrary wave form generator (120) and the said nozzle (113) of the said injector (128) is optional formed for operation mode of atomizing, pulsing and continuous introduction in flow or counterflow direction and the section of the gate of the melt channel (114) is according to the operation mode formed in reducing, continues or expanding shape and the injector is having a Heaterband (159).

20) Device of an apparatus for introduction of additives into melt of plastics or metal according to claims 10 to 18, wherein the system for introduction is consisting of: a pulsing pump connected to a speed controlled motor, and said pump is for instance a crankshaft-inline-, radial-piston- and rotating-valve-version connected to the injectors; or a pump-nozzle-system (124) having a activation by a push-rod and shut-off-valve for operation to the melt (139) immediately attached to the nozzle or activation by frequency controlled solenoid, or as a high pressure pump of an airless spraying system, or as pump of steam spraying system and the said nozzle (113) of the said injector (128) is optional formed for operation mode of atomizing, pulsing and continuous introduction in flow or counterflow direction and the section of the gate of the melt channel (114) is according to the operation mode formed in reducing, continuos or expanding shape and the injector is having a Heaterband (159).

21) Device according to claim 19 for continuous operation (extruder, continuous casting systems) consisting of at least one injector (128) reaching into the melt stream (114) and pressure sensors for the melt (115), for the hydraulic circuit (106) and the medium circuit (102), wherein the hydraulic circuit and the medium circuit is attached to a high pressure pump (101, 105) with a controllable pressure limit valve and the controller for the said pressure limit valve of the media is maintaining a constant differential pressure between medium circuit and melt and hydraulic circuit and medium circuit. FIG. 18

22) Device according to claim 19 for interrupted operation (injection moulding, die casting systems) consisting of at least one injector (128) reaching into the melt stream (114) and pressure sensors for the melt (115), for the hydraulic circuit (106) and the medium circuit (102), wherein for each circuit—the hydraulic circuit (104) and the medium circuit (105)—is connected to a pressure multiplying cylinder (143, 144) and said cylinder is connected to the said system hydraulic (142) and connected to a pressure controller and said multiplying cylinder is pressurized according to the injection cycle and the said medium circuit and hydraulic circuit are loaded by a separate charging pump (101, 105) while the cylinders of the system hydraulic is discharged and the pressure control for the differential pressure is maintained about constant for the medium circuit (p1-p3) and for the hydraulic circuit (p2-p1). FIG. 25

23) Modification of a standard injector according to claim 19, having a combined supply of fuel for the hydraulic circuit and fuel for the medium circuit, wherein the fitting for the supply circuit of the said injector is replaced by a special fitting having a separate boring for hydraulic and medium supply. FIG. 21

24) Modification of a standard injector having two borings in the supply circuit) according to claim 19, having a combined supply of fuel for the hydraulic circuit and fuel for the medium circuit, wherein one boring of the said injector is blocked by a pin and the other circuit is kept open while the blocked circuit is modified by having a second fitting with boring separately. FIG. 22

25) Pump-nozzle-system according to claim 20, wherein the non-return valve of the medium (139) is formed as a spherical, conical or elliptical valve and the injection chamber is configured immediate to said non-return-valve and the spherical-conical valve of the supply channel (137) is having an locking spring (138) pressing the said spherical-conical valve into the valve seat located on the push rod (135) having a supply boring (132) which is connected to the medium circuit. FIG. 23

26) High pressure pump-nozzle-system for airless systems according to claim 20, wherein the non-return-valve of the medium (139) is formed as a spherical-, conical valve and the nozzle-chamber (113) is configured immediate to the said spherical-, conical valve. FIG. 24

27) Method for controlling the device according to claims 19 and 20, wherein the pressure of the hydraulic circuit (106) and of the Medium circuit (102) is activated by a electrical activated pressure limit valve which is regulated by a controller, according to the results of the pressure sensors measuring the melt pressure p₃(115) regulating the pressure p₂of the hydraulic circuit (106) above the pressure p₁of the medium circuit (102) and regulating the said pressure p₁of the medium circuit above the melt pressure p₃(115).

28) Method for controlling the device according to claims 19 and 20, wherein the signal for the activation (108,109,110) of the electro-hydraulic servo-valve (112) of the injector (128) is given by a arbitrary wave form generator (120).

29) Injection nozzle and injection valve according to claims 19 and 20, wherein the interface part (116) is formed for swiveling around the injector axis and optional adjustable for flow- and counter flow-direction injection and the shape of the nozzle is formed according to hydrodynamic laminar flow conditions. FIG. 31 and 32

30) Injection nozzle and injection valve according to claims 19 and 20, wherein the nozzle seat is having sharp edges (172, 173) and radial multiple orifices (167) to obtain atomizing. FIGS. 30 and 33

31) Melt channel according to claims 19 and 20, wherein the melt channel is having variable channel sections to obtain hydraulic speed changes. FIGS. 28 and 29

32) Method of manufacturing extruded profiles of different plastic components in systems consisting of extruder(s), mould and calibrating- and cooling line, wherein the melt stream of at least one extruder in the mould having at least two melt channels is processed by introducing additives for instance hardener, dyes, gas processors, softener, filler, reinforcement ans. into the melt stream by an injector, charging pipe, nozzle, mixing head, porous sinter metal, pump-nozzle, charging device or spraying unit regulating the pressure of the additives according to the pressure of the melt stream and advantageously introduced by pulsation and optional the volume stream of the melt stream is regulated by a throttle valve located at the inlet and mixing of the melt stream after the introduction of the additives by devices for instance pins, mixing shafts and labyrinth and applying shear forces according to the acceleration of the melt by variable channel sections consequently mixing the components having different properties, specific weight to the original material by configuring the melt channel in the mould having variable sections of the channel as there are expansion zones and having junctions inside the mould to unify the melt streams to one stream and subsequently creating a profile consisting of different material components melted together in the mould and passing the following calibrating and cooling section.

33) Apparatus for processing a separately diverged melt stream of an extruded mainstream according to claim 32 by means of distributor, statical mixer, caliber, mandrill, wherein the devices in the melt channel are configured of at least two features, as there are:

inlet with converging section,

pressure sensor reaching the inlet channel, connected to a controller device for variable adjustable section as there are throttle valve, valve, sliding valve;

injector, charging pipe, nozzle, mixing head, porous sinter metal, sliding pump, charger, atomizer reaching into the melt channel;

after the introduction melt channel is configured with

pins, mixing shafts, labyrinth,

variable section, for instance expansion zone.

34) Apparatus for manufacturing extruded profiles of different plastic components in systems consisting of extruder(s), mould and calibrating- and cooling line, wherein the device having an arrangement to divert the melt stream of at least one extruder in the mould into at least two melt channels and having an injector, charging pipe, nozzle, mixing head, porous sinter metal, pump-nozzle, charging device or spraying unit reaching into the melt channel, for introducing additives for instance hardener, dyes, gas processors, softener, filler, reinforcement a/o. into the melt stream and having a regulator for the pressure of the additives connected to a pressure sensor located the melt stream and advantageously having a device for pulsation and optional a throttle valve is located at the melt stream at the inlet, and having a mixer in the melt stream after the introduction of the additives, for instance pins, mixing shafts and labyrinth and having a variable channel sections for application of shear forces according to the acceleration of the melt for mixing the components having different properties, specific weight to the original material and variable sections of the channel as there are expansion zones and having junctions inside the mould to unify the melt streams to one stream and subsequently the melt channel is connected to the mould creating a profile consisting of different material components melted together in the mould and the mould is connected to the following calibrating and cooling section.

35) Apparatus according to claim 33, wherein the divertion of the melt channel, the introduction of the additives, the charging pipeline are located on a interfacing part, mounted in between the flange of the extruder and the flange of the tool.

36) Extruded plastic profile with determined section consisting of at least two components, wherein the said components are derived from at least two melt streams coming from one extruder leading to the mould in separate channels and by introducing additives to these melt streams the properties, for instance specific weight, color, hardness and structure of the matrix are different from the original properties of the extruded component.

37) Device for dosing, dotation and mixing of at least one viscous component with another viscous substance, consisting of an outer nozzle cones and an outer nozzle needle having adjustment devices for dosing or blocking of the outside flowing medium depending on the position of the nozzle needle and said nozzle needle is having a boring, wherein the outer nozzle needle is having a front chamber with the shape of a valve cone orifice or a pocket hole orifice and the said nozzle needle with boring is having an inner nozzle needle having a conical seat for blocking and each nozzle needle having a mechanism for operating the needles respectively.

38) Device consisting of a Hotrunner nozzle in moulds for injection moulding having a outside operated nozzle needle, wherein the said nozzle needle having a boring and having at least one orifice at the needle top and said orifice is in direction rectangular to the needle top at the needle seat and the said nozzle needle is having a connection to a common rail being connected to a high pressure pump supplying constant pressure to the nozzle needle independent to the position of the hot runner nozzle.

39) Device according to the claims 37 and 38, wherein the nozzle needle is having a boring and having orifices, and in the said boring another nozzle needle is located blocking the said orifices according to the activating mechanism attached to the inner nozzle needle.

40) Device according to claims 37 and 38, wherein the needle having the shape of a common rail injector and the said injector is attached to a mechanism for activation and the injector tip is shaped as a nozzle needle and advantageously forming the orifices to reach into the nozzle seat.

41) Device according to claim 39, wherein the gap between the outer nozzle needle and the inner nozzle needle is formed to act as a suction valve for the substances inside the inner nozzle needle.

42) Device according to claims 37 till 41, wherein the device is attached to a subsequent located statical mixing device.

43) Device according to claims 37 to 41, wherein the device is attached to a nozzle of a plastisicing unit of a injection moulding machine.

44) Device according to claims 37 to 41, wherein the device is attached to a the melt channel of an extruder.